Method of molding load-bearing articles from compressible cores and heat malleable coverings

ABSTRACT

Load-bearing articles are manufactured from shape defining compressible cores and thermoplastic shells. The manufacture of these articles requires specific methods and tools. Articles that can be manufactured using these methods include relatively lightweight pallets with high load-bearing capacity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of application Ser. No.10/858,184, filed, Jun. 1, 2004, the entire disclosure of which ishereby incorporated herein by reference.

TECHNICAL FIELD

The invention relates generally to methods of forming load-bearingarticles, such as pallets, by compressing and encasing shape definingcompressible cores within a chemically compatible compression resistantthermoplastic covering.

BACKGROUND

Thermoplastic molding is used to create a wide variety of usefularticles. In general, the process of thermoplastic molding involvesheating a thermoplastic material to its glass transition temperature, atwhich point the material becomes pliable. Other steps in the processinclude shaping the pliable thermoplastic into the shape of a desiredarticle and allowing the article to cool. Once a thermoplastic materialcools to a temperature beneath the range of its glass transitiontemperature the material becomes significantly less pliable andmaintains its new shape. A number of processes have been developed forshaping thermoplastics including single and twin sheet thermoforming.

The twin sheet thermoplastic molding process is often used to createarticles that have a hollow region formed between thermoplastic sheetsjoined to one another at their edges. Examples of articles that have ahollow space between joined thermoplastic sheets include serving pansand thermos bottles. See, for example, U.S. Pat. No. 5,427,732 toShuert, which is herein incorporated by reference in its entirety. Whilesuch articles are clearly useful, most hollow articles are not suitablefor use in load-bearing applications.

Thermoplastics are used to laminate various articles including someload-bearing structures. These methods often involve applyingthermoplastic sheets to a preformed rigid structure. See, for example,U.S. Pat. No. 5,833,796 to Matich, which is herein incorporated byreference in its entirety. The structural component is essentially rigidand a thermoplastic skin is applied to either one or both sides of thestructural component.

The manufacture of articles by twin sheet thermoplastic molding ofteninvolves the use of complimentary male and female molding tools. In onecommon methodology a thin sheet of thermoplastic material is heateduntil it is pliable, and positioned adjacent to a male mold. Thethermoplastic sheet is then moved relative to the tool's surface untilthe sheet assumes the same shape as the surface of the tool.

Similarly, a second sheet of thermoplastic material is heated until itbecomes pliable. The heated second sheet is then centered over thecavity of a female molding tool and moved relative to the female toolmolding until the interior portion of the second sheet substantiallyconforms to the interior shape of the female tool.

One variation of this method, sometimes referred to as vacuum-assistmolding, uses vacuum to help draw heated thermoplastic sheets intocontact with the surface of the tools. Irrespective of how they areformed, after the two thermoplastic sheets have taken on the shapes ofthe male and female molds, the edges of the sheets are pressed togetherand welded to form a single article. For a further discussion ofvacuum-assist thermoplastic molding, see, for example, U.S. Pat. No.5,641,524 to Rush et al., which is hereby incorporated by reference inits entirety.

Vacuum-assist molding works well to manufacture articles that haveconvex or shallow concave features. The method does not work as well tomanufacture articles that have deep narrow concave features. If thefemale mold cavity is too deep or the sides of the mold too steep, theattractive force supplied by vacuum alone may be insufficient toproperly seat the sheet on the interior surface of the female mold.

One method developed to address this problem is referred to asplug-assist molding. Briefly, in plug-assist molding, a rigid tool isused to push a heated sheet at least partly into the cavity of a secondtool with a surface shape complimentary to the shape of the first tool.It is easier to manufacture articles that have deep narrow featuresusing plug-assist molding, than it is to manufacture these types ofarticles using vacuum-assist molding. For an additional discussion ofplug-assist molding, see, for example, U.S. Pat. Nos. 6,379,606 to Chunet al., and 5,641,524 to Rush et al., both of which are herebyincorporated by reference in their entirety.

Plug-assist molding works well, but it too has some limitations. The useof the plug-assist molding method is problematic if the goal is toproduce articles with load-bearing capabilities. Problems arise becauseplug-assist molding tends to produce articles that have an unevendistribution of thermoplastic material across the surface of thearticle. This occurs because the edges of the thermoplastic sheet areclamped in place while the plug contacts the interior of the sheet. Asthe plug advances material gathers on the leading face of the plug,stretching and thinning the portion of the sheet between the clampededges and the leading face of the plug. As a result, articles formed bysimple plug-assist may have relatively thick edges, bottoms and tops,and relatively thin sides.

An uneven distribution of material resulting in an article with thinsides is especially problematic if the article is used in a load-bearingcapacity. The side sections join the top and bottom of the article, andin many load-bearing articles the sides support the top. In theseapplications the sides bear most of the load and since the sides arethinned in plug-assist molding, articles produced using this techniquemay be weaker than expected given the composition and thickness of thestarting materials.

One way to correct problems caused by differential thinning is to beginthe process by using thicker thermoplastic sheets. Another approach isto add additional thermoplastic material to specific portions of thearticle while it is being formed. See, for example, U.S. Pat. No.5,885,691 to Breezer et al., which is hereby incorporated by referencein its entirety. Other methods for addressing this problem have alsobeen advanced. See, for example, U.S. Pat. No. 5,427,732 to Shuert,which is hereby incorporated by reference in its entirety.

Given the limitations of currently used methods for making load-bearingarticles from thermoplastics and the myriad of potential uses forload-bearing thermoplastics articles, there is a need for additionalmethods and machinery for the manufacture of such articles.

One area in need for strong, lightweight, load-bearing articles is themanufacture of pallets. Most pallets are designed for use with standardforklift trucks and crane lift cradles and are used throughout the worldfor the storage and transportation of goods. The majority of pallets inuse worldwide are manufactured primarily from wood.

Wood is easy to work with, inexpensive, and well known in thewarehousing and transportation industries. These properties account forthe widespread use of wood in the manufacture of pallets. However, theuse of wood in the manufacture of pallets does have some drawbacks. Forexample, wooden pallets absorb moisture, rot, splinter, and may harborpests. The propensity of wooden pallets to harbor pests means thatwooden pallets may inadvertently transport harmful fungi, bacteria, andinsects between different eco-systems. The introduction of pests into alocal eco-system via wooden packing materials, including wooden pallets,can have devastating effects on the local ecosystem.

Given the problems associated with wood-based pallets, there is a realneed for pallets made from inexpensive, easy to manufacture, stable, andbiologically inert materials, such as plastics. Examples of pallets madeat least in part from plastics, can be found in U.S. Pat. Nos. 3,915,098to Nania, and 6,216,608 to Woods et al. and in U.S. Patent ApplicationPublication Number 2002/0112653 A1 to Moore, et al. All of theaforementioned references are herein incorporated by reference in theirentirety. Despite the existence of these and other plastic-based palletsthe continued widespread use of wooden pallets demonstrates the need foradditional plastic based pallets.

Clearly, there is a need for load-bearing pallets constructed of stable,inexpensive, easily formed, and relatively inert materials, as well asmethods and apparatus for manufacturing such pallets.

SUMMARY OF THE INVENTION

Some aspects of the present invention relate to load-bearing articleshaving compressible shape forming cores as well as apparatus and methodsof manufacturing these articles. Various aspects of the invention arenovel, nonobvious, and provide various advantages. While the actualnature of the invention covered herein can only be determined withreference to the claims appended hereto, certain forms and features,which are characteristic of the preferred embodiments disclosed herein,are described briefly as follows.

One embodiment is a method for forming load-bearing articles fromcompressible shape forming core members and compatible thermoplasticshells. The compressible core members are used as plugs in plug-assistmolding processes to help shape the shell of a load-bearing article. Thecompressible core members used to shape the thermoplastic shell becomepart of the manufactured article and help to strengthen and stabilizethe article. The compressible member, as a part of the manufacturedarticle, continues to resist compression. The expansive force exerted bythe core member trying to expand against the constraining force exertedby the shell strengthens the bond between the shell and the corethroughout the useful life of the article.

Another embodiment is an apparatus for forming load-bearing articlescomprised of compressible shape defining core members and thermoplasticshells. In one embodiment, a compressible core member is stacked orsandwiched between two heated thermoplastic sheets. The sandwich iscompressed and corresponding portions of the two sheets contact oneanother and bond together. The core member bonds to the interior surfaceof the thermoplastic shell as the core member tries to expand andcontacts portions of the thermoplastic shell.

Another embodiment is a load-bearing article including a shape definingcompressible core member at least partially compressed with athermoplastic shell. In one embodiment, the compressed core member isbonded to at least a portion of the interior of the thermoplastic shell.

The gross shape of most of the articles manufactured using the methodsof these embodiments are largely determined by the gross shape of theshape defining compressible core member.

Further embodiments, objects, features, aspects, forms, advantages andbenefits shall become apparent from the description and drawingscontained herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. An exploded perspective view of three components of aload-bearing article.

FIG. 2. A stylized side view of one embodiment illustrating steps in theprocess of forming load-bearing articles. A heated thermoplastic sheetis positioned between a shape-forming core and a female mold.

FIG. 3. A stylized side view of one embodiment illustrating steps in theprocess of forming load-bearing articles. A heated thermoplastic sheetis engaged with one surface of a shape-forming compressible core.

FIG. 4. A stylized side view of one embodiment illustrating steps in theprocess of forming load-bearing articles. A heated thermoplastic sheetis engaged with one surface of a shape-forming compressible core and aperforated inner surface of a female mold.

FIG. 5. A stylized side view of one embodiment illustrating steps in theprocess of forming load-bearing articles. A heated thermoplastic sheetis engaged with one surface of a shape-forming compressible core and aperforated inner surface of a second molding tool and a first moldingtool disengaging from a surface of the shape forming compressible coremember.

FIG. 6. A stylized side view of one embodiment illustrating steps in theprocess of forming load-bearing articles. A heated thermoplastic sheetis engaged with one surface of a shape-forming compressible core and aperforated inner surface of a female mold. A second heated thermoplasticsheet positioned between the first platen and a surface of ashape-forming compressible core member.

FIG. 7. A stylized side view of one embodiment illustrating steps in theprocess of forming load-bearing articles. A first heated thermoplasticsheet is engaged with one surface of a shape-forming compressible coreand a perforated inner surface of a female mold. A second heatedthermoplastic sheet is engaged with a surface of a compressible coremember and the surface of the first platen.

FIG. 8. A top view of one embodiment, a pallet formed in part bycompressing a shape-forming compressible core member between two heatedthermoplastic sheets.

FIG. 9. A side view of the front of one embodiment, a pallet formed inpart, by compressing a shape-forming compressible core member betweentwo heated thermoplastic sheets.

FIG. 10. A side view of one side of one embodiment, a pallet formed inpart, by compressing a shape-forming compressible core member betweentwo heated thermoplastic sheets.

FIG. 11. A perspective view of the underside of one embodiment, a palletformed in part, by compressing a shape-forming compressible core memberbetween two heated thermoplastic sheets.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustratedherein, and specific language will be used to describe the same. Itwill, nevertheless, be understood that no limitation of the scope of theinvention is thereby intended. Any alterations and further modificationsin the described processes, systems, or devices, and any furtherapplications of the principles of the invention as described herein, arecontemplated as would normally occur to one skilled in the art to whichthe invention relates.

The term “molding” as used in this application refers to the shaping ofa pliable material to assume a new desired shape. Molding may involvethe use of specific molding tools such as male and female molding tools,sculptured platens, and the like. It may also include the use ofspecifically shaped core members including compressible core membersthat are used to impart a desired shape to at least a portion of athermoplastic material.

The term “convex” is to be given its broadest possible definition. Theterm convex, refers to a three dimensional object that has at least onefeature protruding from the perspective of at least one other surface ofthe same or an adjacent article. For example, a rectangular shapedobject with a given length, width, and height is considered convex asthe profile formed by any 5 contiguous sides protruding from the planedefined by the sixth side of the rectangle.

The term “chemically compatible” refers to materials that can form bondswith one another. Chemically compatible materials include, for example,thermoplastics that have similar glass melting temperatures as well asthermoplastic materials that have glass melting temperature ranges,which overlap one another. For example, when chemically compatiblematerials in contact with one another are both at a temperature in theirrespective glass transition range and allowed to cool bonds form betweenthe materials.

In one embodiment bonding between compatible materials occurs bypolymerization. These chemically compatible materials are heated totheir glass melting temperatures, held in contact with one another, andcooled together to polymerize and thereby form lasting bonds between thecontacting portions of the materials. One method for the manufacture ofload-bearing articles having both structural components andthermoplastic shells is similar to laminating the structural elementwith thermoplastic material. See, for example, U.S. Pat. No. 6,224,706to Matich, herein incorporated by reference in its entirety. Vacuum isused to

One embodiment of the present invention is a method for the manufactureof various articles including load-bearing articles, which includesusing a shape forming compressible core member to shape, stabilize, andstrengthen a load-bearing article. The compressible core member iscompressed during the molding process and continues to try and expandagainst the compressive contraction of the thermoplastic shell evenafter the article cools. In one embodiment the method includes using acombination of heat and pressure to create bonds between chemicallycompatible compressible core members and thermoplastic sheets.

One embodiment includes the steps of using a shape defining core memberto substantially shape a thermoplastic sheet. The core member is atleast partially enveloped by at least a portion of the sheet. Theenveloped portion of the core member is at least partially compressed bythe enveloping sheet and resists further compression. The portion of thethermoplastic sheet enveloping the corresponding portion of the coremember resists expansion of the core material. The combination ofexpanding core member and expansion resistant envelope promotes andstrengthens bonding between portions of the core member andthermoplastic sheet in contact with one another.

Still another embodiment is a molding method, which includes the stepsof shaping a thermoplastic shell to partially conform to the shape ofcompressible core member. The volume of the core member, in itsuncompressed form, is greater than the volume of the space formed byclosure of the male and female molds. In this method the core is stacked(sandwiched) between two heated thermoplastic sheets positioned betweenmale and female molds. As the molds are brought closer together thesandwich is compressed. Portions of the core and two sheets, as well ascorresponding portions of the two sheets are brought into contact withone another.

Once compressed, the article is held under pressure until the articlecools enough for bonds to form between portions of the sandwich incontact with one another. For example, bonds form between the edges ofthe two sheets in contact with one another. Similarly, core materialsand thermoplastic sheet materials in contact with one another bondtogether as they cool.

One embodiment is a molding method that produces load-bearing articles,which are stronger and more durable than load-bearing articles formedfrom similar materials using different molding processes.

One embodiment is a matched tooling process wherein at least a portionof one of the molding tools is comprised of a shape definingcompressible core member. The core member includes at least one feature,which is substantially complimentary to a feature in a matching moldingtool. In one embodiment the compressible core member may include bothmale and female features, while the corresponding matching molding toolincludes male and female features complimentary to the features in thecompressible core member.

Still another embodiment includes the use of a concave female moldingtool, a flat platen, and a convex shape defining compressible coremember. While the overall shape of the convex portion of the core memberis substantially complimentary to the concave shape of the femalemolding tool, the volume of the convex portion of the core member islarger than the volume of the interior of the female molding tool.

In one embodiment the compressible core member is used like a male toolin plug-assist molding process to drive a sheet of heated thermoplasticinto the interior of the female molding tool. A stack, also referred toas a sandwich, is formed comprising the core member positioned betweentwo heated thermoplastic sheets. The two thermoplastic sheets are sizedand positioned such that regions of the two sheets, especially theiredges, contact one another when the core is compressed between them.

In one embodiment the entire sandwich is compressed between a flatmolding tool and the interior of the female molding tool. The coremember and heated thermoplastic sheets are comprised of chemicallycompatible materials that bond to one another as heat is transferredbetween the heated sheets and core member. As the article cools, bondsform between sections of the article in contact with one another,including contacting sections of the thermoplastic sheets and compressedcore member.

Still another embodiment is an apparatus for the manufacture ofload-bearing articles from shape defining compressible core members andchemically compatible thermoplastic materials.

Yet another embodiment is a load-bearing article comprised of compressedshape defining core members and chemically compatible thermoplasticshells. A partial list of load-bearing articles that can be made inconformity with the methods of the present invention and the industriesthey may be utilized in are found in Table I.

TABLE I Examples of load-bearing articles that can be manufactured witha shape defining compressible core member and a thermoplastic shell.Also, following is an abbreviated list of industries that can use sucharticles. A/C Shells Air Cargo Containers Boards Boat Parts BulkheadsCargo boxes Dunnage Firewalls Golf Cart Top/Body Helmets Infant carseats Insulated Storage Lockers and Chests Lawn Tractor Covers Lumberalternatives Medical equipment housings Medical imaging tables PadsPallets Panels Portable flooring Race Seats Roadside sound barriers RVparts Safety barriers Spas/Tubs/Enclosure Storage containers Surgicaltables Tonneau covers Tractor Top/Cab Truck Cabs Vehicle side panelsVehicle bumpers

These articles can be used in a wide variety of industries including,but not limited to, the following:

Aerospace Appliance Automotive Construction Defense FurnitureElectronics Food High Technology Medical Packaging/LogisticsPharmaceuticals Sports

Some of the thermoplastic materials that can be used in combination withchemically compatible core members to form articles according to someembodiments of the invention are listed in Table II.

TABLE II List of some of the thermoplastic materials that can be used incombination with chemically compatible core members to form load-bearingarticles. Thermoplastic Olefin (TPO) Polypropylene/Polypropylenecomposite (sold under the trade name CURV) Polycarbonate (PC) HighImpact Polystyrene (HIPS) Low Density Polyethylene (LDPE) High DensityPolyethylene (HDPE) Polypropylene (PP) Polyphenylene Ether alloyed withHigh Impact Polystyrene (sold under the trade name NORYL)

Thermoplastic sheet and shell materials including those listed in TableII may also include additives including, for example, plasticizers,dyes, pigments, hardeners, releasing agents, UV stabilizers, and thelike as are known in the art.

One brand of TPO that may be used in this embodiment is SEQUEL E3000available from SOLVAY. Table III includes a summary of the physical andchemical properties of SEQUEL E3000.

TABLE III Summary of some of the physical and chemical properties of onebrand of TPO, SEQUEL E3000 available from SOLVAY. PROPERTY TYPICAL VALUEUNITS ASTM METHOD¹ Hardness 65 Shore D D-2240 Specific Gravity 1.07D-792 Melt Flow Rate 1.3 g/10 min D-1238 (230° C., 2.16 kg load)Procedure A Shrink 0.007-0.009 in/in D-955 Flexural Modulus 300,000 psiD-790 (2,069) (MPa) I.B., TAN, 2 mm/min Tensile Strength @ 3,100 psiD-638 Yield (21) (MPa) Elongation @ Break 275 % D-638 Gardner Impact @23° C. >320 (36) in-lb (J) D-5420-96 @ −30° C. 310 (35) in-lb (J)D-5420-96 Notched Izod Impact @ 23° C. 18.5 NB ft-lb/in D-256 @ −30° C.3.1 PB ft-lb/in D-256 HDT @ 66 psi 230 (110) ° F. (° C.) D-648 @ 264 psi140 (60) ° F. (° C.) D-648 CLTE (−30° C. to 2.67 × 10⁻⁵ in/in/° F. D-69680° C.) (4.81 × 10⁻⁵) (mm/mm/° C.) Modified UL94 Flammability HB (allcolors) Underwriters Laboratory Inc. ¹Test performed in accordance withmethods developed by ASTM International, 100 Barr Harbor Drive, PO BoxC700, West Conshohocken, PA, 19428-2959 USA.

A partial list, of some materials that can be used to formshape-defining compressible core members for use in some embodiments ofthe invention are listed in Table IV.

TABLE IV Some materials that can be used in combination with chemicallycompatible thermoplastics to form compressible core members. ExpandedPolypropylene (EPP) Polystyrene (EPS) A blend of polyphenylene ether(PPE) and polystyrene (PS) impregnated with pentane (one such materialis sold under the trade name GECET) A blend of polyphenylene ether (PPE)and polystyrene (PS) impregnated with pentane (one such material is soldunder the trade name CARIL) Polyethylene (EP)

The articles, apparatus, and methods of the invention can be adapted foruse with a wide variety of materials, machinery, and processes widelyused in thermoplastic molding. For example, rotary wheel twin-sheetthermoforming can be adapted for the practice of some of the embodimentsof the invention. See, for example, U.S. Pat. No. 6,379,606 to Chun etal., herein incorporated by reference in its entirety. Other methods andmachinery known in the art can also be used to practice some of theembodiments of the invention.

A number of figures and illustrations are provided by way ofexplanation, not limitation. Throughout these figures and illustrations,like numbers are used whenever possible to refer to like components,elements, steps, and the like.

Referring now to FIG. 1, three elements 10 of a load-bearing article areillustrated, a first thermoplastic sheet 20, a shape defining coremember 30, and a second thermoplastic sheet 40. In one embodiment theseelements are combined to form a load-bearing article, as illustrated,for example, in FIG. 11. First thermoplastic sheet 20 and secondthermoplastic sheet 40 are heated until they are pliable. The exacttemperature range will depend upon the specific thermoplastic materialsincluded in sheets 20 and 40.

Referring again to FIG. 1, first thermoplastic sheet 20 has a firstsurface 22 and a second surface 24. First thermoplastic sheet 20 may becomprised of any of a variety of thermoplastic materials that havephysical and chemical properties suitable for the method and article ofmanufacture.

Still referring to FIG. 1, components for the manufacture of aload-bearing article in accordance with one embodiment include a shapedefining compressible core member 30. Core member 30 has a first surface32 and a second surface 34. In one embodiment second surface 34 of coremember 30 is substantially flat, while first surface 32 of core member30 has a convex interior and arcuate tapered edges 33.

In still another embodiment, first surface 32 of core member 30 includesboth male (convex) 32 and female (concave not shown) features asassessed from the perspective of second surface 34.

In one embodiment first sheet 20 is comprised of TPO having a thickness28 ranging from about 0.04 inches to about 0.08 inches. In anotherembodiment first sheet 20 is comprised of TPO having a thickness 28 ofabout 0.04 inches.

In one embodiment second sheet 40 is comprised of TPO having a thickness48 ranging from about 0.04 inches to about 0.08 inches. In anotherembodiment second sheet 40 is comprised of TPO having a thickness 48 ofabout 0.04 inches.

Still referring to FIG. 1, thermoplastic sheet 40 has a first surface42, and a second surface 44. Second thermoplastic sheet 40 may becomprised of any of a variety of thermoplastic materials that havephysical and chemical properties suitable for the method and article ofmanufacture. Thermoplastics suitable for use in sheet 40 includethermoplastics selected from the list of materials found in Table II.

Still referring to FIG. 1, in one embodiment the length 27 of firstsheet 20 and the length 47 of second sheet 40 are substantially the samewhile the length 37 of core member 30 is substantially less than thelengths 27 and 47 of first sheet 20 and second sheet 40, respectively.Similarly, the width 26 of first sheet 20 and the width 46 of secondsheet 40 are substantially the same, while the width 36 of core member30 is substantially less than the widths 26 and 46 of first sheet 20 andsecond sheet 40, respectively.

FIGS. 2-7 illustrate at least two embodiments. One embodimentillustrated in FIGS. 2-7 is a method for forming load-bearing articleshaving a shape defining compressible core and a shell formed from atleast two heated thermoplastic sheets. An additional embodimentillustrated in FIGS. 2-7 is components of an apparatus that may be usedto form load-bearing articles having a shape defining compressible coreand a shell formed from at least two heated thermoplastic sheets.

Referring now to FIG. 2, a stylized side cross-sectional view 50illustrates some of the steps and some of the components of theapparatus used in at least one embodiment. First platen 60 has a firstsurface 62, and is operatively connected to drive 55. Drive 55 isoperatively connected to a means (not shown) for moving first platen 60relative to other components of the apparatus. Drive 55 may be actuatedmechanically, pneumatically, hydraulically, or by any other means knownin the art.

Still referring to FIG. 2, operatively positioned beneath first surface62 of platen 60 is shape forming compressible core member 30. The secondsurface 34 of core member 30 is complimentary in shape to the firstsurface 62 of first platen 60. Operatively positioned directly beneaththe first surface 32 of core member 30 is heated pliable firstthermoplastic sheet 20. The edges of first sheet 20 are operativelyconnected to clamping frame 70. Clamping frame 70 operatively positionsfirst sheet 20 such that the interior, but not the edges, of first sheet20 are positioned between first surface 32 of core member 30 and thefirst surface 82 of mold 80. Typically, thermoplastics used in theprocess are heated until they are pliable using either infrared orconvection heating, a combination of the two, or any other suitablemeans of heating thermoplastics known in the art.

Referring still to FIG. 2, in one embodiment the bottom of molding tool80 rests on, or is attached to, optional second platen 90. Optionally,second platen 90 is operatively connected to drive 95. Drive 95 isoperatively connected to a means (not shown) for moving second platen 90relative to other components of the apparatus, for example, first platen60. Drive 95 may be actuated mechanically, pneumatically, hydraulically,or by any other means known in the art.

As illustrated in FIG. 2, surface 62 of platen 60 (or an optional firstmolding tool, not shown) are perforated. A plurality of channels 64extend through platen 60 and are operatively connected to a vacuumsource (not shown). As illustrated in FIG. 3, vacuum may be applied tochannels 64 and used to operatively hold core member 30 in the center ofthe first surface 62 of platen 60. As illustrated in FIG. 3, in oneembodiment mold 80 has a perforated first surface 82, holes in surface82 are operatively connected to a plurality of channels 84. Channels 84,extending through mold 80, are operatively connected to a vacuum source(not shown).

Still referring to FIG. 3, clamping frame 70 holding the perimeter ofheated first thermoplastic sheet 20 advances relative to mold 80 suchthat a portion of the edge of sheet 20 is in contact with the uppermostedge 86 of mold 80. Next core member 30 attached to first surface 62 ofplaten 60 through vacuum 66 applied to channels 64 are advanced towardsfirst thermoplastic sheet 20. The movement of core member 30 relative tofirst sheet 20 may be accomplished by moving platen 60 via activation ofdrive 55, or by moving platen 90 via activation of drive 95, or movingboth first platen 60 and second platen 90 relative to one another. Firstsurface 82 of mold 80 is complimentary (in general shape) to firstsurface 32 of core member 30.

Referring now to FIG. 4, the volume defined by the perimeter ofcompressible core member 30 is larger than the interior volume of thespace defined by contacting the edge of first platen 60, surface 62 andthe edge 86 of mold 80. Once sheet 20 and core member 30 are in positionthe distance between mold 80 and platen 60 is decreased. The distance isdecreased until the perimeter of heated first thermoplastic sheet 20 ispressed between the uppermost outer surface 86 of mold 80 and the edgeof surface 62 of first platen 60.

Referring again to FIG. 4, advancing first platen 60 until the edge offirst sheet 20 is pressed against the uppermost edge 86 of mold 80compresses core member 30. At this stage in the process vacuum 66 tochannel 64 (see FIG. 3) is turned off. And as illustrated in FIG. 4vacuum 85 is applied to channels 84 through mold 80. Next (referring nowto FIG. 5) platen 60 is withdrawn relative to mold 80. Vacuum 84 ismaintained to hold sheet 20 in contact with surface 82 of mold 80. Heatinduced bonding between core member 30 and first thermoplastic sheet 20holds core member 30 substantially in place.

Referring now to FIG. 6, platen 60 is withdrawn relative to mold 80 atleast far enough to allow second thermoplastic sheet 40 to beoperatively positioned between first surface 62 of platen 60 and secondsurface 34 of core member 30. In one embodiment, heated secondthermoplastic sheet 40 is held in place by clamping the edges of sheet40 to optional second clamping frame 75.

In one embodiment, vacuum 64 (as shown in FIG. 5) is applied to surface62 of platen 60 to help, shape, stabilize, and position second sheet 40,positioned between core member 30 and platen 60 as illustrated in FIGS.6 and 7. Once sheet 40 is firmly in contact with the core member 30 andthe edges of sheet 20 the vacuum to platen 60 may be turned off.

Referring now to FIG. 7, once heated second thermoplastic sheet 40 isoperatively positioned between first surface 62 of first platen 60 andsecond surface 34 of compressible core member 30, the distance betweenfirst platen 60 and mold 80 is decreased. In one embodiment the distancebetween platen 60 and molding tool 80 is decreased by moving platen 60through activation of drive 55. In another embodiment the distancebetween platen 60 and molding tool 80 is decreased by activating drive95 operatively attached to second platen 80 which supports (or isattached to) mold 80. In yet another embodiment, moving both firstplaten 60 and second platen 80 decreases the distance between platen 60and mold 80.

Still referring to FIG. 7, the distance between platen 60 and moldingtool 80 is decreased until the edge of heated second thermoplastic sheet40 contacts the edges of heated first thermoplastic sheet 20 resting onedge 86 of mold 80. Once the edges of first thermoplastic sheet 20 andsecond thermoplastic sheet 40 contact one another the interior of heatedsecond thermoplastic sheet 40 contacts and further compresses coremember 30. In one embodiment vacuum 85 through channels 84 in moldingtool 80 is maintained throughout these steps to insure that first sheet20 remains in contact with interior surface 82 of molding tool 80.

Platen 60 and molding tool 80 are held in place. Portions of sheets 20and 40 in contact with one another, for example, the edges 86 bondedtogether. Bonding can be promoted by use of ultrasonic or hot airwelding. The components are held in place under pressure until thearticle cools and the bond between sheets 20 and 40 strengthens. In oneembodiment virtually the entire surface of compressible core member 30remains in contact with the interior of the space between firstthermoplastic sheet 20 and second thermoplastic sheet 40.

In one embodiment heat from heated first thermoplastic sheet 20 and heatfrom heated second thermoplastic sheet 40 promotes bonding between theinterior surface of the shell formed by thermoplastic sheet 20 and 40and the surface of compressed core member 30.

Embodiments, in addition to the ones illustrated in FIGS. 1-11, areenvisioned and claimed. By way of example, and not of limitation, someof these embodiments are as follows.

One embodiment is a method for forming load-bearing articles comprisinga shape defining compressible core and a thermoplastic external shell.This method includes the steps of providing a shape definingcompressible core member that is larger before it is compressed than itis after it is compressed and incorporated into a load-bearing article.Additional steps include stacking the core member between chemicallycompatible heated thermoplastic sheets, using a first platen and secondplaten. The second platen may include an optional attached secondmolding tool. The mold has a first surface complimentary to the shape ofthe first surface of the shape-forming compressible core member. Thesandwich can be compressed by moving either, or both, the first andsecond platens towards one another. The core-compressing step alsobrings complimentary portions of the first and second heatedthermoplastic shells into contact with one another. Pressure is appliedto the sandwich until the article cools forming bonds between portionsof the thermoplastic shell in contact with one another.

In one embodiment portions of the two sheets in contact with one anotherare welded together. Welding may be performed using ultrasonic welding,hot air welding, or any other suitable means known in the art.

In one embodiment bonds also form between portions of the compressedcore member in contact with the interior surface of the thermoplasticshell.

In one embodiment the first platen (or optionally a first molding toolattached to the first platen) includes a means for reversibly attachinga shape forming compressible core member to the first surface of theplaten. Such means include, for example, a set of perforations in thefirst platen surface connected to a vacuum source. Vacuum is used toreversibly attach an operatively positioned core member to the surfaceof the first platen. Next a heated thermoplastic sheet attached to aclamping frame is positioned between the first surface of the coremember and the surface of the mold. A clamping frame is sized andpositioned such that the frame itself does not interfere with therelative movement of the first platen and mold relative to one another.The clamping frame holds the first heated thermoplastic sheet andmaintains the original length, width, and shape of the perimeter of thesheet. In one embodiment the first platen moves the core member intocontact with the interior of the heated sheet.

The core member partially compresses once it contacts the interior ofthe first heated pliable thermoplastic sheet. The interior of the firstheated sheet deforms and at least partially conforms to the contour ofthe first surface of the core member. The first platen continues toadvance moving both the core member and the interior portion of theheated first thermoplastic sheet until the sheet contacts the firstsurface of the molding tool attached to the second platen. This pressesa portion of the first heated sheet between the core member and interiorsurface of the mold. In one embodiment heat transfer between the coremember and first heated sheet promotes the formation of bonds betweenportions of the core member and first sheet in contact with one another.

In one embodiment the interior surface of the molding tool attached tothe second platen is perforated. These perforations are connected to avacuum source. When the first heated sheet nears the surface of thesecond molding tool, vacuum is applied to the surface of the secondmolding tool to help hold the first heated sheet to the surface of thesecond molding tool.

In a subsequent step vacuum is withdrawn from the first molding toolthereby releasing the core member from the surface of the first platen.The first platen is withdrawn at least far enough to allow a secondheated thermoplastic sheet to be positioned between the first moldingtool and the second surface of the core member. The second heatedthermoplastic sheet may be attached to an optional second clampingframe.

The clamping frame operatively positions the heated second thermoplasticsheet between the first platen and the molding tool housing the firstthermoplastic sheet and partially compressed core member. The optionalsecond clamping frame also helps to maintain the original length, width,and shape of the perimeter of the second heated sheet. Next, thedistance between the first and second platens is reduced until thesecond heated sheet contacts the interior portion of the second surfaceof the core member. Similarly, as the distance between the platensdecreases complimentary portions of the first and second heated sheetscontact one another. In one embodiment the platens come to rest relativeto one another when the core member is compressed and the edges of thefirst heated thermoplastic sheet are pressed together.

Pressure is maintained on the stack (sandwich) formed by the firstheated sheet, compressed core member, and second heated sheet until thearticle cools enough for bonds to form between sections of the twothermoplastic sheets in contact with one another. In one embodiment asthe article cools bonds also form between the surface of the compressedcore member and interior surface of the thermoplastic sheets in contactwith one another.

In one embodiment the edges of the two sheets in contact with oneanother are pinched together to ensure a strong bond between the edgesof the first and second heated sheets.

In a final series of steps the article is removed from between the firstand second platens. In an optional step excess material is trimmed fromthe exterior of the article.

Parameters known in the art to impact the quality of the article formedand the efficiency of the process can be controlled throughout theprocess. This includes parameters such as heat, pressure, vacuum, timingof each step, and the like. The process can be automated to varyingdegrees depending, in part, upon the equipment used and the discretionof the operator.

In one embodiment the shape defining compressible core member is shapedby steam chest molding using an aluminum mold before the core member isincorporated into a load-bearing article.

In one embodiment the materials comprising the shell (thermoplasticsheets) and the compressible core are chemically compatible. In oneembodiment these materials bond together when they are heated, held incontact with one another, and permitted to cool together. Examples ofcompatible thermoplastic sheet and compressible core members includecombinations such as TPO and EPP, or HDPE and PE, or other combinationsof chemically compatible thermoplastic materials and compressible coremembers as are known in the art.

In one embodiment, heat from the heated thermoplastic sheetsencapsulating the compressible core member promotes bonding between thecore member and heated thermoplastic sheet comprising the shell of thearticle.

In another embodiment, the surface of the shape defining core member iscoated with a thermo-activated adhesive before it is placed in contactwith, and compressed between, the heated thermoplastic sheets comprisingthe shell of the article.

Another embodiment is an apparatus for manufacturing load-bearingarticles comprising a shape defining compressible core member andthermoplastic shell. Components of the apparatus include a first platenand a second platen movable with respect to one another. In oneembodiment the platens can be moved so as to decrease or increase thedistance between the platens. The platens can be moved by any of thefollowing means: mechanical, pneumatic, hydraulic, or any combination ofmeans thereof, or any other means known in the art.

In one embodiment the first molding tool attached to the first platenincludes a perforated first surface. The perforations in the firstsurface are connected to a vacuum source. Vacuum is controllably appliedto reversibly attach a shape defining compressible core member to thefirst surface of the first platen.

At least one surface of the molding tool is complimentary to the contourof at least one surface of the shape defining compressible core member.In one embodiment a mold is associated with a second platen. In anotherembodiment a mold replaces the need for a second platen.

In still another embodiment a second platen replaces the need for aseparate molding tool. This second platen has a surface that iscomplimentary to the contour to at least one surface of the shapedefining compressible core member.

In one embodiment the mold includes a series of perforations in thesurface of the mold facing the complimentary surface of the core member.The perforations in the surface are connected to a vacuum source.

In one embodiment the mold is a female mold with a concave interiorsurface complimentary to the convex surface of the shape definingcompressible core member. The volume defined by the concave interior ofthe female mold is less than the volume defined by complimentary convexshape of the uncompressed compressible core member.

In one embodiment the apparatus further includes a means for heatingthermoplastic sheets to a temperature range suitable for shaping thesheets and forming bonds between sheets. Means for heating thethermoplastic sheets include infrared, convection heating, combinationsof thereof, and any other suitable means known in the art.

In one embodiment the apparatus includes a means for attaching, holding,and positioning heated thermoplastic sheets between the platens of theapparatus. In one embodiment these means for sheet handling includes atleast one clamping frame. The interior of the clamping frame is largeenough to hold the heated sheet such that the first platen and top edgeof the mold (or top edge of the second platen) can move relative to oneanother without contacting the clamping frame.

In one embodiment the apparatus includes a means for cooling thearticle. Cooling means include devices that directly apply coolingsprays comprising, for example, air, water, and the like to the article.Alternatively, cooling devices may operate to cool the article bycooling components of the device in direct or indirect contact with thearticle.

In one embodiment the apparatus further includes a steam-molding chestfor shaping the compressible core member before it is incorporated inthe article.

In another embodiment the apparatus includes a pinching mechanism forapplying directed pressure to the edges of the first and second heatedsheet in direct contact with one another. In one embodiment the edges ofthe two heated sheets in contact with one another are kept underpressure until the article cools and bonds form between the edges of thesheet in contact with one another.

In still another embodiment the apparatus includes a means for applyinga coating of thermo-activated adhesive to the surface of the coremember. Adhesive is applied before the core member is placed in contactwith the heated thermoplastic sheets comprising the thermoplastic shell.The adhesive may be applied by use of a sprayer, roller, dipper, or anyother means for coating a surface known in the art. Alternatively,thermo-activated adhesives may be applied directly to portions of theheated thermoplastic sheets that are intended to contact one another orportions of the core member.

One embodiment is a load-bearing article comprising a shape definingcompressible core member compressed within a shell includingthermoplastic components.

In one embodiment the materials included in the core member and in thethermoplastic shell are chemically compatible. Chemically compatiblematerials bond together when they are heated, held in contact with oneanother, and allowed to cool.

In one embodiment the thermoplastic shell comprises a plurality ofsheets shaped to conform to the contour of the compressed shape of theshape defining core member. The sheets are bonded to one another alongthe edges of the sheets. In one embodiment, the two sheets are bonded toone another, at least one other area of contact between the two sheets(in addition to the edges of the article).

In one embodiment the compressible core member, is further compressed asthe thermoplastic shell cools and contracts.

In one embodiment the shape defining compressible core member is firstshaped by steam chest molding before the core member is incorporatedinto a load-bearing article. One means for steam chest molding that maybe used includes an aluminum mold.

In one embodiment the thermoplastic sheet material includesthermoplastic olefin (TPO). TPO may be supplemented with compounds,including but not limited to, talc, calcium carbonate, and variouspressing aids known in the art.

In one embodiment, the sheets of TPO used to form the shell range inthickness from about 0.04 to 0.08 inches.

In another embodiment the sheets of TPO used to form the shell range inthickness from the shell is about 0.04 inches.

In one embodiment the materials comprising the shell (thermoplasticsheets) and the compressible core are chemically compatible. In oneembodiment these materials bond together when they are heated, held incontact with one another, and permitted to cool together. Examples ofcompatible thermoplastic sheet and compressible core members includecombinations such as TPO and EPP, or HDPE and PE, or other combinationsof chemically compatible thermoplastic materials and compressible coremembers as are known in the art.

In one embodiment the article is a pallet. Pallets made using themethods of this invention include pallets suitable for use in a widevariety of applications. Table V lists some of the defining propertiesof some of pallets that can be made according to some embodiments of theinvention. Table V also includes information on the applications forthese pallets and the industries where they are likely to be used.

TABLE V Properties of specific types of pallets, and some specificapplications for pallets with these properties. Pallet PropertyApplication Industry Cost Effective any shipping all Reusable anyshipping all (especially closed loop Light Weight any shipping allErgonomic Any shipping all Durable any shipping all 4-way Entry anyshipping all Non-slip Surface any shipping all Moisture Resistant anyshipping all Water Repellant, any shipping all Draining Pest Resistantany shipping all Shock Absorption High High tech value/sensitiveperishable cargo Fire Retardant any shipping all Aesthetics any shippingall Easily Modified all all Multicolor Option Food, all manufacturing,chemical Recyclable any shipping all Mold/Mildew any shipping allresistant Stackable/ any shipping all Nestable Rigid —rackable anywarehousing all Compatible with Any warehousing all conveyors/application material handling systems Smooth Surface SanitaryFood-interplant, requirements pharmaceutical Insulating Perishable Food,pharmaceuticals, biotechnology Bandable High tech, heavy Highvalue/heavy industry Chemical Resistant Chemical, Chemical,pharmaceutical pharmaceutical Repairable Any shipping All with closedloop Temperature Food Food Resilient Anti static Electronics, High tech,chemical flammables UV resistant Any shipping all Radio FrequencyPrimarily high Pharmaceuticals, Identification value or time Food, hightech; (RFID) tag sensitive tracked inventory Sealed all all DifferentSizes all all

Referring now to FIG. 8, one embodiment is pallet 150. Pallet 150includes a deck 151 having an upper surface 152 and lower surface 156(illustrated in FIG. 11). Referring again to FIG. 8, upper surface 152of deck 151 is substantially flat. In one embodiment upper surface 152includes grooves (not shown), perpendicular to the front edge 170, andparallel to the edge 172 of pallet 150. Although not shown the uppersurface 152 may include a variety of features to add surface area andhelp to prevent materials placed on surface 152 from sliding off pallet150.

Still referring to FIG. 8, as illustrated pallet 150 includes nine legs160, arranged in three sets of three legs in each set. Each leg 160 iscontiguous with lower deck 156 (see FIG. 11). Each leg 160 has asubstantially elongated oval shape 174 where it protrudes from lowersurface 156 of pallet 150. Each leg has a substantially round bottom176. The round bottom 176 of each leg 160 is substantially flat andparallel with the upper surface 152 of deck 151.

Referring again to FIG. 8, two pairs of grooves 178 are formed in thelower surface 156 of pallet 150. Grooves 166, illustrated in side view,are optionally placed in pairs between each adjacent set of three legs160. Thermoplastic sheets used to form the upper 152 and lower 156 (seeFIG. 11) surfaces of deck 151 (referring again to FIG. 8) are joinedtogether along edge 168. These sheets are also joined together by aseries of bonding spots (divots) 164 located one between each adjacentset of legs 160.

Referring now to FIG. 9, a side view 190, of the front of pallet 150.Upper surface 152 and lower surface 156 of deck 151 are joined bytapered edge 162. The twin thermoplastic sheets comprising upper surface152 and lower surface 156 are joined together along edge 168 and atbonding points 164. The slightly oval shaped bottom 176 of leg 160 isjoined to the top 177 of leg 160 by leg side 175. Legs 160 are conicaland tapered from where leg 160 joins the lower surface 156 of deck 151.

Referring now to FIG. 10, a side view 200, of the side of pallet 150.The distance 175 between legs 160 along side view 200 is less than thedistances 177 between legs 160 illustrated in view 190 shown in FIG. 9.In this embodiment distances 177 (FIG. 9) and 175 (FIG. 10) are madesuch that it is easier for forks to slide between legs 160 from front170 (as illustrated in FIG. 8) than from side 172 (as illustrated inFIG. 9).

Referring now to FIG. 11, a perspective view 210 of pallet 150. Thebottom 180 of leg 160 has a partially recessed surface 176 is offset bythe width of edge 182. The side 184 of leg 160 is parallel to the side172 of pallet 150 and parallel to the front 170 of pallet 150. The front182 of leg 160 is contiguous with the side 184 of leg 160. The portionof leg 160 where it emerges from lower surface 150 of deck 151 has anelongated oval shape 177.

Still referring to FIG. 11, tapered edge 162 joins upper surface 152(shown in FIG. 8) of deck 151 with the lower surface 156 (shown in FIG.11) of deck 151. In one embodiment thermoplastic sheet comprising uppersurface 152 (shown in FIG. 8) and lower surface 156 (shown in FIG. 11)of deck 151 are joined together along edge 168 and at various bondingspots (divots) 164. Grooves 178 extend parallel to side 172. Each groove178 is substantially rectangular in shape having a width 192, a depth194 and a length 198. The length 198 of groove 178 is less than thelength measured from the front of first leg 160 a to the back of thirdleg 160 c.

Again referring to FIG. 11, divots 164 are domed shaped featuresextending through the depth of 162 of deck 150 to join the thermoplasticsheets comprising upper deck surface 152 and lower deck surface 156. Inone embodiment these features 164 are positioned between each adjacentpair of support legs 160. Features 144 contribute to the strength andstability of pallet 150, in part, by providing points of contact andbonding between upper deck 152 and lower deck 156. The dome shape of 164also helps to strengthen pallet 150.

The dome shape of 164 serves to distribute some of the downward force ofloads place on upper deck 152 to the lateral components of lower decksurface 156. This distribution of load to the flat areas of 156buttressing the bottom of domed divot 164 adds to the load-bearingcapacity of pallet 150. Divots 164 also increase the surface area 192 ofcontact between the shell 214 and core 216 of pallet 150, as illustratedin cut away 212. In one embodiment core member 216 is bonded to theinterior of the shell 214. Bonding between core 216 and shell 214contributes to the strength and durability of pallet 150. Therefore byincreasing the bonding surface between core 216 and shell 214 divots 164help to strengthen and stabilize pallet 150.

Still referring to FIG. 11, as illustrated in cutaway 212, compressiblecore member 216 substantially fills all spaces formed by the interior oflegs 160 and deck 151. The surface of core member 216 is substantiallyin contact with the interior surface of shell 214 bounded by the insidesurfaces of legs 160 and deck 151.

In addition to the embodiment illustrated in FIGS. 8-11, additionalpallet structures are also within the scope of the invention. Theseembodiments include the following.

In one embodiment foot members are positioned to support the deck and toallow ready transport of the pallet by forklift trucks, shipping cranecradles, and the like.

In one embodiment the pallet has nine legs. The nine legs are arrangeduniformly in three sets of three legs each. Each leg is a conical oval;wider where it emerges from the bottom of the first deck and narrower ata point furthest from the deck.

In another embodiment the pallet has six legs. The six legs areuniformly arranged in three rows of two legs each.

In one embodiment the upper surface of the deck is comprised of a secondthermoplastic sheet and the lower surface of the deck and the legs arecomprised of a first thermoplastic sheet. The two sheets are joinedtogether at the edge of the deck and at additional areas evenly spacedbetween each pair of legs. In these regions, much like at the edge ofthe deck, there is no compressed core member material between the bondedthermoplastic shell components.

In one embodiment the upper surface of the pallet deck includes groovesor other features that aid in creating a skid resistant surface.

In one embodiment the shell of the pallet is made from materialincluding thermoplastic olefin (TPO). One type of TPO that may be usedin the manufacture of the pallet is SEQUEL E3000 available from SOLVAY.Any thermoplastic with similar chemical and physical properties may alsobe used in the manufacture of the pallet.

In one embodiment the TPO used in the shell of the pallet furtherincludes talc, calcium carbonate and/or pressing aids.

In one embodiment the exterior of the pallet is comprised of sheets TPOwith a thickness in the range of about 0.04 to 0.08 inches.

In another embodiment the exterior of the pallet is comprised of sheetsTPO with a thickness of about 0.04 inches.

In one embodiment the compressible core member of the pallet includesExpandable Polypropylene (EPP). In one embodiment the compressible coremember of the pallet includes EPP, with a density in the range of about1.9 to 5.0 pounds per cubic foot (lbs./ft.³).

In another embodiment the compressible core member of the palletincludes EPP, with a density of about 1.9 pounds per cubic foot(lbs./ft.³).

One embodiment is a pallet comprising a shape defining compressible coremember and a thermoplastic shell chemically compatible with the coremember. One such pallet is manufactured by compressing a core membercomprising Expandable Polypropylene (EPP) with a density of about 1.9 toabout 5.0 foot pounds per cubic foot (lbs./ft.³) with a thermoplasticolefin (TPO). In one embodiment two sheets of TPO on the order of 0.04to 0.08 inches thick are used to create the shell and help compress thecore member.

EXAMPLES

For the purpose of promoting further understanding and appreciation ofthe present invention and its advantages, the following Examples areprovided. It will be understood, however, that these Examples areillustrative and not limiting in any fashion.

Example 1

A Four-Station Rotary Twin Sheet Thermoformer manufactured by BROWN wasused to produce a load-bearing article in the shape of a pallet. Thefinished pallet was 24 inches wide and 40 inches long. The pallet hadtwo sets of three legs each (one set of legs fewer than the palletillustrated in FIGS. 8-11).

The pallet was constructed from two 28 inch wide by 44 inch long sheetsof Thermoplastic Olefin TPO. The TPO used in this example wasmanufactured by SOLVAY and has brand name SEQUEL E3000. Each sheet ofTPO was on the order of 0.04 inches thick. The pallet core member wasapproximately 24 inches wide and 40 inches long. The overall shape ofthe core member included two sets of three legs.

The setting of the Thermoforming Machine used are listed in Table VI.

TABLE VI Machine settings for the BROWN Four-Station Rotary Twin SheetThermoformer used in manufacture the pallet of Example 1. FORM FUNCTIONCYCLE FORM FUNCTION CYCLE TIMERS SECONDS TIMERS SECONDS Top Plat DownLong 0.10 Top Plat Up Long 56.00 Top Plat Down Short 0.10 Top Plat UpShort 8.00 Bot Plat Up Long 5.00 Bot Plat Down Long 54.00 Bot Plat UpShort 2.00 Bot Plat Down Short 10.50 Cooling Fans On 20.00 Cooling FansOff 45.00 Rimlock Long Cycle 60.00 Rimlock Short Cycle 17.00 CoolingDelay 250 Clamp Frame Open in 10.00 Form Lube Cycle Count 10 Lube CycleDuration 3.00 VACUUM FORMING VACUUM FORMING FUNCTIONS SECONDS FUNCTIONSSECONDS Top Main Vac #1 On 0.00 Top Main Vac #1 Off 0.00 Top Main Vac #2On 4.00 Top Main Vac #2 Off 53.00 Bot Main Vac #1 On 9.00 Bot Main Vac#1 Off 50.00 Bot Main Vac #2 On 0.00 Bot Main Vac #2 Off 7.00 Top AirEject #1 On 0.00 Top Air Eject #1 0.00 Off Top Air Eject #2 On 55.00 TopAir Eject #2 56.50 Off Bot Air Eject #1 On 53.00 Bot Air Eject #1 54.50Off Bot Air Eject #2 On 7.00 Bot Air Eject #2 8.00 Off Vacuum Bleed #1On 7.00 Vacuum Bleed #1 Off 50.00 Vacuum Bleed #2 On 0.00 Vacuum Bleed#2 Off 0.00 Vacuum Pull #1 On 0.00 Vacuum Pull #1 Off 0.00 Vacuum Pull#2 On 3.00 Vacuum Pull #2 Off 8.00 Vacuum Dump #1 On 0.00 Vacuum Dump #1Off 0.00 Vacuum Dump #2 On 0.00 Vacuum Dump #2 Off 0.00 Vacuum Blow #1On 0.00 Bubble Blow #1 Off 0.00 Vacuum Blow #2 On 0.00 Bubble Blow #2Off 0.00 PRESSURE FORMING PRESSURE FORMING FUNCTIONS SECONDS FUNCTIONSSECONDS Platen Locks On 9.00 Platen Locks Off 52.00 Air Bags On 10.00Air Bags Off 49.00 Inlet Needle #1 In 16.00 Inlet Needle #1 Out 45.00Mold Pressure #1 On 11.00 Mold Pressure #1 40.00 Off Outlet Needle #1 In0.00 Outlet Needle #1 0.00 Out Inlet Needle #2 In 9.00 Inlet Needle #2Out 45.00 Mold Pressure #2 On 11.00 Mold Pressure #2 40.00 Off OutletNeedle #2 In 0.00 Outlet Needle #2 0.00 Out PLATEN SEQUENCE FUNCTIONSINCHES Top Platen 20.00 Retracted Top Plat Ret Start 6.00 2-Speed TopPlat Ext 9.50 (Short) Stop 2- Speed Top Plat Ext (Long) 6.50 Stop2-Speed Top Plat Extended 5.00 (Short) Top Plat Extended 1.50 (Long) BotPlat Extended 9.25 (Short) Bot Plat Extended 12.25 (Long) Bot Plat Ext13.25 (Short) Stop 2- Speed Bot Plat Ext (Long) 17.00 Stop 2-Speed BotPlat Ret Start 14.00 2-Speed Bottom Platen 28.00 Retracted Vacuum Bleed#1 on 0.00 Position Vacuum Bleed #2 on 0.00 Position LIFT TABLEFUNCTIONS INCHES Lift Table Extended 14.00 Lift Table Mid 20.00 PositionLift Table 50.00 Retracted

The shape defining compressible core member was comprised of EPP. Thecore member had a substantially flat upper surface and a lower surfacethat included both convex and concave features. The core member includedsix convex conical ovals, six convex divots, and four grooves. The sixconvex conical ovals were in the shape of pallet support legs. The topsof the conical ovals were wider than the bottoms. The six conical voidswere arranged in two sets of three voids each. A row of voids was placedbetween each pair of adjacent conical ovals. A pair of grooves bracketedeach set of conical voids. Each groove ran parallel to the long axis ofthe conical oval shaped convex features. The total volume of thecompressible core member was demonstratively larger before it wascompressed than after it was compressed and incorporated into thepallet.

A first sheet of heated pliable TPO attached to a molding frame waspositioned over the interior of a female molding tool. The core memberattached by vacuum to the first platen of the Thermoformer was pushedthrough the first sheet. The first platen was advanced until the coremember partially compressed and the first thermoplastic sheet madecontact with the interior surface of the female molding tool. Residualheat in the first sheet of TPO helped to form a connection between thecore member and the first sheet.

Vacuum was applied to the interior surface of the female molding tool tohelp hold the first sheet and the contacting core member within theinterior of the female molding tool. The vacuum to the first platen wasturned off and the core member was released from the first platen.

A second heated pliable sheet of TPO was attached to a molding frame andpositioned between the first platen and interior of the female moldingtool. The first platen was advanced until the core member compressed andthe edges of the first and second sheets were compressed between theoutermost flat edges of the first platen and female mold. Compressingthe core member also caused the two thermoplastic sheets to contact eachother between the holes in the top of conical voids of the core member.

All portions of the pallet where the first and second sheets of TPOcontacted one another were heat welded. The pallet was removed from theRotary Thermoformer. Excess thermoplastic material was removed from theedges of the pallet.

Visual and tactile examinations of the pallet showed that the coremember was in substantial contact with all regions of the thermoplasticshell, except for the portions of the pallet where the two sheets are indirect contact with one another. Inspection of the regions of the twoTPO sheets in direct contact with one another show that after heatwelding the two sheets have bonded well to one another.

The present invention contemplates modifications as would occur to thoseskilled in the art. It is also contemplated that processes embodied inthe present invention can be altered, rearranged, substituted, deleted,duplicated, combined, or added to other processes as would occur tothose skilled in the art without departing from the spirit of thepresent invention. In addition, the various stages, steps, procedures,techniques, phases, and operations within these processes may bealtered, rearranged, substituted, deleted, duplicated, or combined aswould occur to those skilled in the art.

All publications, patents, and patent applications cited in thisspecification are herein incorporated by reference, as if eachindividual publication, patent, or patent application was specificallyand individually indicated to be incorporated by reference and set forthin its entirety herein.

Further, any theory of operation, proof, or finding stated herein ismeant to further enhance understanding of the present invention and isnot intended to make the scope of the present invention dependent uponsuch theory, proof, or finding.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is considered to beillustrative and not restrictive in character, it is understood thatonly the preferred embodiments have been shown and described and thatall changes and modifications that come within the spirit of theinvention are desired to be protected.

1. A method of forming articles including a shape defining compressiblecore member, and a thermoplastic external shell, said method comprisingthe steps of: providing a shape defining compressible core memberincluding a first surface and a second surface, wherein at least onesurface includes a pattern of features, said core member being comprisedof expanded polymer; positioning said core member adjacent to a firstheated pliable thermoplastic sheet that is without a preformed contour,to form a stack including said first sheet and said core member, whereinsaid first pliable thermoplastic sheet is longer and wider than saidcore member; compressing said stack between a first molding tool, and asecond molding tool, wherein said first molding tool has a surface atleast as long and as wide as said core member, and said second moldingtool has a surface at least as long and as wide as said core member anda contour complimentary to the features of said at least one surface ofsaid core member, wherein said core member is used as a plug assist tomove said sheet into the contour of said second molding tool whencompressing said stack; and holding said stack between said first andsaid second molding tools until said stack cools and bonds form betweenportions of said core member and said sheet in contact with one another.2. The method according to claim 1, further including the steps of:providing a perforated first surface for said interior of surface ofsaid second molding tool; and supplying vacuum to perforations in aninterior of said first surface of said second molding tool such thatsaid vacuum can be used to draw and hold said thermoplastic sheet intoclose contact with the contour of said perforated first surface of saidsecond molding tool.
 3. The method according to claim 1, wherein thedistance between said first and said second molding tools is decreasedby moving said first molding tool towards said second molding tool. 4.The method according to claim 1, wherein the distance between said firstand said second molding tools is decreased by moving said second moldingtool towards said first molding tool.
 5. The method according to claim1, wherein said expanded polymer of said core member comprises acompressible material selected from the group consisting of: Polystyrene(PS), a blend of polyphenylene ether (PPE) and polystyrene (PS)impregnated with pentane, a blend of polyphenylene ether (PPE) andpolystyrene (PS) impregnated with pentane, Polyethylene (PE) andPolypropylene (PP).
 6. The method according to claim 1, wherein saidfirst thermoplastic sheet has a thickness from about 0.04 inches toabout 0.08 inches.
 7. The method according to claim 1, wherein said coremember and said first thermoplastic sheet comprise materials that bondto one another when said materials are heated and held in contact withone another.
 8. The method according to claim 1, wherein said coremember has an uncompressed volume that is greater than a volume of aspace formed by closure of said first and second molding tools.
 9. Themethod according to claim 1, including the step of, providing a secondheated pliable thermoplastic sheet, wherein said second sheet isintroduced into said process in an orientation substantially parallel tothe orientation of said first thermoplastic sheet so as to sandwich saidcore member between said first sheet and said second sheet forming saidstack, compressing said stack and holding said stack between said firstand second molding tools until said stack cools and bonds form betweenportions of said core member and said second sheet in contact with oneanother.
 10. The method according to claim 9, wherein said first andsaid second sheets continue to compress said core member as said stackcools and said thermoplastic sheets contract.
 11. The method accordingto claim 9, wherein heat transferred from said first and said secondheated sheets to the core member promotes bonding between the surfacesof said core member and said first and said second sheets.
 12. Themethod according to claim 9, wherein said thermoplastic sheets comprisea thermoplastic material selected from the group consisting of:Polypropylene/Polypropylene composite, Polycarbonate (PC), High ImpactPolystyrene (HIPS), Low Density Polyethylene (LDPE), High DensityPolyethylene (HDPE), Polypropylene (PP), and Polyphenylene Ether alloyedwith High Impact Polystyrene.
 13. The method according to claim 9,including the step of: coating said core member with a thermo-activatedadhesive before compressing said stack.
 14. The method according toclaim 9, wherein said core member and said first and said secondthermoplastic sheets comprise materials that bond to one another whensaid materials are heated and held in contact with one another.
 15. Themethod according to claim 14, wherein the volume of said core member isgreater before said core member is compressed between said first andsaid second sheets than after said core member is compressed betweensaid first and said second sheets.
 16. The method according to claim 9,wherein said core member comprises Expanded Polypropylene (EPP) and saidfirst and said second thermoplastic sheets comprise thermoplastic olefin(TPO).
 17. The method according to claim 16, wherein said TPO furtherincludes talc, calcium carbonate, and pressing aids.
 18. The methodaccording to claim 16, wherein said TPO is about 0.04 to about 0.08inches thick.
 19. The method according to claim 16, wherein said firstsheet of TPO is about 0.08 inches thick and said second sheet of TPO isabout 0.04 inches thick.
 20. The method according to claim 16, whereinsaid first and said second sheets are about 0.04 inches thick.
 21. Themethod according to claim 16, wherein said EPP has a density rangingfrom about 1.9 to about 5.0 pounds per cubic foot (lbs./ft.³).
 22. Themethod according to claim 16, wherein said EPP has a density of about1.9 pounds per cubic foot (lbs./ft.³).
 23. The method according to claim16, wherein said core member is shaped by steam chest molding beforesaid core member is provided to form said article.
 24. The methodaccording to claim 1, further including the steps of: providing a firstclamping frame and a second clamping frame wherein both said first andsaid second clamping frames are larger than said first and said secondmolding tools; attaching said heated first thermoplastic sheet to saidfirst clamping frame; carrying out said compressing step; attaching aheated second thermoplastic sheet to said second clamping frame;positioning said second sheet between said first molding tool and saidcore member; compressing said stack that includes said core sandwichedbetween said first sheet and said second sheet; and holding said stackbetween said first and said second molding tools until said stack coolsand bonds form between portions of said core member and said secondsheet in contact with one another.
 25. A method of forming articlescomprising the steps of: providing a compressible core member thatincludes a first surface and a second surface, wherein said secondsurface of said core member includes a contour; providing a heatedthermoplastic sheet adjacent said core member, said sheet being withouta preformed contour; positioning said core member and said sheet betweenfirst and second molding tools; wherein said second molding tool has acontour that is complementary to the contour of said core member andsaid core member has an uncompressed volume that is greater than avolume of a space formed by closure of said first and second moldingtools; compressing said core member and said sheet together between saidfirst and second molding tools, wherein said core member is used as aplug assist to move said sheet into the contour of said second moldingtool and wherein the core member is compressed to a compressed volumethat is received by the volume of the space formed by closure of saidfirst and second molding tools; and holding said core member and saidsheet between said first and said second molding tools until said coremember and said sheet cool and bonds form therebetween.
 26. The methodof claim 25 further comprising: positioning a heated secondthermoplastic sheet between said first molding tool and said coremember; compressing said core member and said first and second sheetsbetween said first and second molding tools; and holding said coremember and said first and second sheets between said first and saidsecond molding tools until said core member and said first and secondsheets cool and bonds form therebetween.
 27. The method according toclaim 25, wherein said thermoplastic sheet has a thickness from about0.04 inches to about 0.08 inches.
 28. A method of forming articlescomprising the steps of: providing a compressible core member thatincludes a first surface and a second surface, wherein said secondsurface of said core member includes a contour; providing a heatedthermoplastic sheet adjacent said core member, said sheet being withouta preformed contour; positioning said core member and said sheet betweenfirst and second molding tools; wherein said second molding tool has acontour that is complementary to the contour of said core member andsaid core member has an uncompressed volume that is greater than avolume of a space formed by closure of said first and second moldingtools; compressing said core member and said sheet together between saidfirst and second molding tools, wherein said core member is compressedto a compressed volume that is received by the volume of the spaceformed by closure of said first and second molding tools; and holdingsaid core member and said sheet between said first and said secondmolding tools until said core member and said sheet cool and bonds formtherebetween.
 29. The method of claim 28, further comprising:positioning a heated second thermoplastic sheet between said firstmolding tool and said core member; compressing said core member and saidfirst and second sheets between said first and second molding tools; andholding said core member and said first and second sheets between saidfirst and said second molding tools until said core member and saidfirst and second sheets cool and bonds form therebetween.
 30. The methodaccording to claim 28, wherein said first thermoplastic sheet has athickness from about 0.04 inches to about 0.08 inches.